Eaton XC-152 Series User manual

Manual
XC-152
Compact Controller
05/17 MN050001ZU EN

Compact PLC XC-152 05/2017 MN050001ZU EN www.eaton.com
Brands and products are trademarks or registered trademarks of their owners.
Break-Down Service
Please call your local representative:
http://eaton.eu/aftersales
or
Hotline After Sales Service:
[phone] (de, en)
[e-mail]
Original operating manual
The German-language edition of this document is the original operating manual.
Translation of the original operating manual
All editions of this document other than those in German language are translations of
the original operating manual.
2nd. edition 2017
for further editions see list of revisions
© 2013 by Eaton Industries GmbH, 53105 Bonn
Editorial editing:Antje Panten-Nonnen
Translation:GLOBALDOCS GmbH, Düsseldorf
All rights reserved, also for the translation.
No part of this manual may be reproduced, stored in a retrieval system, or transmit-
ted in any form or by any means, electronic, mechanical, photocopying, micro-film-
ing, recording or otherwise, without the prior written permission of Eaton Industries
GmbH, Bonn.
Subject to alteration.

1
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that are live.
• Follow the engineering instructions (AWA/IL) of the
device concerned.
• Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on
this device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the
protective earth (PE) or to the potential equalisation. The
system installer is responsible for implementing this
connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference does not impair
the automation functions.
• Install automation devices and related operating elements
in such a way that they are well protected against
unintentional operation.
• Suitable safety hardware and software measures should
be implemented for the I/O interface so that a line or wire
breakage on the signal side does not result in undefined
states in the automation devices.
• Ensure a reliable electrical isolation of the low voltage for
the 24 volt supply. Only use power supply units complying
with IEC 60364-4-41 (VDE 0100 Part 410) or HD 384.4.41 S2.
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation.
• Emergency stop devices complying with IEC/EN 60204-1
must be effective in all operating modes of the automation
devices. Unlatching the emergency-stop devices must not
cause restart.
• Devices that are designed for mounting in housings or
control cabinets must only be operated and controlled
after they have been installed with the housing closed.
Desktop or portable units must only be operated and
controlled in enclosed housings.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This
should not cause dangerous operating states even for a
short time. If necessary, emergency-stop devices should
be implemented.
• Wherever faults in the automation system may cause
damage to persons or property, external measures must
be implemented to ensure a safe operating state in the
event of a fault or malfunction (for example, by means of
separate limit switches, mechanical interlocks etc.).
Eaton Industries GmbH Safety instructions
Danger!
Dangerous electrical voltage!

2

Compact PLC XC-152 05/17 MN050001ZU DE www.eaton.com 1
Table of Contents
0 About this manual ..................................................................... 5
0.1 Target group................................................................................. 5
0.2 List of revisions ............................................................................ 5
0.3 Documents with additional information ....................................... 6
0.4 Reading conventions.................................................................... 7
0.4.1 Hazard warnings of material damages ......................................... 7
0.4.2 Hazard warnings of personal injury .............................................. 7
0.4.3 Tips............................................................................................... 7
1 Description.................................................................................. 9
1.1 Function ....................................................................................... 9
1.1.1 Features ...................................................................................... 9
1.1.2 Options......................................................................................... 9
1.1.3 SWD coordinator special feature ................................................. 10
1.2 Intended use ................................................................................ 10
1.3 Part numbers................................................................................ 11
1.4 Operator control and display elements ........................................ 12
1.5 Front............................................................................................. 12
1.6 Service side.................................................................................. 13
1.7 Accessory devices ....................................................................... 14
1.8 Nameplate.................................................................................... 14
1.9 Support......................................................................................... 15
1.10 Marine approvals.......................................................................... 16
2 Safety regulations...................................................................... 17
2.1 Basics........................................................................................... 17
2.2 Mandatory requirements, personnel requirements ..................... 17
2.2.1 Occupational safety...................................................................... 17
2.2.2 Personnel qualifications ............................................................... 18
2.2.3 Device documentation ................................................................. 18
2.2.4 Prerequisites for proper operation ............................................... 18
2.3 Device-specific hazards................................................................ 19

2Compact PLC XC-152 05/17 MN050001ZU DE www.eaton.com
3 Installation.................................................................................. 25
3.1 Prerequisites for the location of use ............................................ 25
3.1.1 Installation position ...................................................................... 25
3.2 Conditions for marine approval (DNV GL) .................................... 26
3.2.1 Radio interference suppression filter for the 24 V DC supply...... 27
3.3 Communication cables................................................................. 28
3.3.1 Preparing the cables with the SUB-D plug................................... 29
3.3.2 Screening the communication cables used ................................. 30
3.4 Unpacking and checking the equipment supplied ....................... 31
3.5 Mounting ..................................................................................... 32
3.5.1 DIN-rail mounting......................................................................... 33
3.5.2 Screw fixing ................................................................................. 34
3.6 Preparing the device for operation............................................... 35
3.6.1 Power supply 24 V DC................................................................. 36
4 Commissioning .......................................................................... 39
4.1 Initial Commissioning................................................................... 40
4.1.1 Configuring the system settings.................................................. 40
4.1.2 Connect Computer and XC-152 in the network........................... 41
4.1.3 Connect Computer and XC-152 connected directly with a cable. 41
4.1.4 Setting the IP address with an SD card ....................................... 41
4.2 Running the XC-152..................................................................... 42
4.3 External memory.......................................................................... 43
4.3.1 Inserting and removing the SD card ............................................ 43
5 External connections................................................................. 45
5.1 Layout overview........................................................................... 46
5.2 USB interfaces............................................................................. 47
5.2.1 USB device .................................................................................. 47
5.2.2 USB Host ..................................................................................... 47
5.3 Ethernet ....................................................................................... 48
5.4 Serial interfaces to other devices................................................. 49
5.4.1 RS232 (System Port).................................................................... 50
5.4.2 RS485 .......................................................................................... 51
5.4.3 CAN ............................................................................................. 53
5.4.4 Profibus........................................................................................ 55
6 XC-152 as a SmartWire-DT coordinator .................................. 59
6.1 SmartWire-DT operator control and display elements ................. 59
6.1.1 POW/AUX SWD power supply .................................................... 60
6.1.2 SWD master interface ................................................................. 62

Compact PLC XC-152 05/17 MN050001ZU DE www.eaton.com 3
7 Malfunctions............................................................................... 65
8 Maintenance ............................................................................... 67
8.1 Cleaning and maintenance ........................................................... 67
8.1.1 Battery.......................................................................................... 67
8.2 Repairs ......................................................................................... 67
8.3 Storage and transport................................................................... 68
8.4 Disposal........................................................................................ 69
9 Technical data ............................................................................ 71
9.1 Dimensions and weights.............................................................. 71
9.2 System ......................................................................................... 72
9.3 Power supply ............................................................................... 73
9.4 Interfaces ..................................................................................... 74
9.5 SmartWire-DT Master .................................................................. 76
9.5.1 POW/AUX (power supply interface for SmartWire-DT)................ 76
9.5.2 SWD (SmartWire-DT interface) .................................................... 77
9.6 Approvals and declarations .......................................................... 78
9.7 Applied standards and directives ................................................. 78
9.8 Environmental conditions............................................................. 79

4Compact PLC XC-152 05/17 MN050001ZU DE www.eaton.com

0 About this manual
0.1 Target group
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 5
0 About this manual
This manual contains all the information you will need in order to use the
XV300 safely and effectively. The XC-152 manual is considered an integral
part of the devices and must always be readily available in their close proxim-
ity so that users have access to it.
This manual describes all of the devices' lifecycle stages: transportation,
installation, commissioning, operation, maintenance, storage, and disposal. It
assumes you have electrical engineering knowledge and skills.
It does not, however, go over the corresponding operating system or applica-
tion software.
Please send any comments, recommendations, and suggestions concerning
this document to: [email protected]
0.1 Target group
This manual is intended for engineers, electricians, and automation techni-
cians. Electrical engineering and physics-related knowledge and skills, as
well as advanced familiarity with the field bus being used, will be required in
order to be able to commission the corresponding devices.
In addition, readers must be familiar with how to use the SmartWire-DT sys-
tem.
0.2 List of revisions
The following table only lists major modifications.
CAUTION
Installation requires qualified electrician
Publication
date
Page Keyword New Modifica-
tion
01/2013 New edition ✓
12/2014 expansion ✓
05/2017 Revision, Marine approvals, SWD ✓✓

0 About this manual
0.3 Documents with additional information
6Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com
0.3 Documents with additional information
For more information on the operating system and application software, as
well as on additional devices and modules, please refer to the following doc-
uments:
•Installation instructions XC-152 IL05003006Z
•User manual XSOFT-CODESYS 2 MN05003007Z 
PLC programming XC-152
(explains how to use the XSoft-CoDeSys-2 programming tool and the
PLC runtime system for the XC-152 device model with Windows CE)
•User Manual XSOFT-CODESYS 3 MN048008ZU, 
PLC programming
The following documents may also be helpful in relation to the use of this
device:
•System Description Windows CE MN05010007Z 
(operation of the Windows CE operating system on touch displays)
•Networks in Brief MN05010009Z
(information on networks in general and on how to integrate PCs and
touch displays in networks)
In addition to the information in this document, you will also need the infor-
mation in the following documents in order to set up a SWD- network and
install and operate it using the SWD- master.
•Manual SmartWire-DT The SystemMN05006002
(system description, engineering, installation, commissioning, and diag-
nostics for a SWD network)
•Manual SWD- modules (IP20) MN05006002Z
Manual SWD- Modules IP67MN120006
(setup, engineering, installation, etc. for the individual SWD modules)
The SWD-Assist planning and ordering program can be extremely useful
when planning and configuring an SWD- network in terms of hardware and
software.
SWD-Assist is available for download free of charge at Eaton's website.
The aforementioned documents, as well as the manual you are reading right
now, can also be downloaded free of charge in PDF format at:
http://www.eaton.eu/doc
￫Enter the document number ("IL05003006Z" or "MN05003007Z",
for example) or "XC-152" into the Quick Search text field.

0 About this manual
0.4 Reading conventions
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 7
For the latest information on the product, please visit the Automation, Con-
trol & Visualization section at:
http://www.eaton.eu/xc-152
Eaton Online Catalog
Enter "XC-152" into the search box and the catalog will take you directly to
the corresponding product group in the Automation, Control and visualization
section. 
http://www.eaton.eu/ecat
0.4 Reading conventions
Symbols used in this manual have the following meanings:
▶Indicates instructions to be followed.
0.4.1 Hazard warnings of material damages
0.4.2 Hazard warnings of personal injury
0.4.3 Tips
NOTICE
Warns about the possibility of material damage.
CAUTION
Warns of the possibility of hazardous situations that may possi-
bly cause slight injury.
WARNING
Warns of the possibility of hazardous situations that could result
in serious injury or even death.
DANGER
Warns of hazardous situations that result in serious injury or
death.
￫Indicates useful tips.

0 About this manual
0.4 Reading conventions
8Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com

1 Description
1.1 Function
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 9
1 Description
1.1 Function
XC-152 Compact Controllers are programmable logic control (PLC) systems
with field bus interfaces.
With their computing power, SmartWire-DT interface, and a broad range of
additional interfaces, XC-152 Compact Controllers make it possible to imple-
ment cost-effective solutions for automation tasks.
An important feature is their ability to be integrated in modern communica-
tion concepts. Data exchange via the Ethernet interface to OPC clients or the
integrated WEB servers enables the creation of innovative solutions. 
The compact PLCs combine PC performance with a range of communication
interfaces.
1.1.1 Features
•24 V DC power supply
•RUN/STOP switch and LED displays
•OPC Server
•Web-server
•Remote Server
•OS: Windows CE 5.0 (License incl.)
•Processor: RISC CPU, 32 bit, 400 MHz
•Program, data, and retentive tag memory: 
Application: 64 MB / Flags: 4 KB / Retentive data: 32 KB
•External memory: 1 SD memory card slot
•Programming: CODESYS
•Target visualization: GALILEO/CODESYS (remote visualization capabili-
ties)
•Communication interfaces
USB (USB device 2.0, USB host 2.0)
10/100 Mbps Ethernet port
1.1.2 Options
•Additional communication interfaces depending on the specific model: 
SmartWire-DT, RS232, RS485, PROFIBUS/MPI, and CAN

1 Description
1.2 Intended use
10 Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com
1.1.3 SWD coordinator special feature
XC-152-E... devices featuring the optional SmartWire-DT interface can be
used as SWD coordinators for Lean Automation.
1.2 Intended use
XC-152 compact PLCs are used primarily in machine and system building
applications. They are intended exclusively for operating and controlling
machines and systems. 
The device is designed to be flush mounted in control cabinets, control pan-
els, or control consoles.
Any other use must be discussed and agreed upon with the manufacturer in
advance.
XC-152 compact PLCs are approved for use in closed spaces.
￫SmartWire-DT can prove to be invaluable when implementing
Eaton's Lean Automation concept, which, as part of the com-
pany's Lean Solution approach, offers several significant advan-
tages. More specifically, SmartWire-DT integrates the I/O level
directly into the switchgear being used, enabling a PLC to use
SmartWire-DT to directly access digital and analog data from
control circuit devices all the way to circuit-breakers. This elimi-
nates the need for a separate gateway and I/O layer, reducing
the number of components and engineering work and enabling
users to create flexible, yet streamlined automation solutions.
Eaton calls this concept Lean Automation, and uses it to provide
users in the machine building and plant engineering industries
with unparalleled freedom so that they can design creative and
profitable solutions.
WARNING
The XC-152 must be used only in locations for which the XC-152 is approved.
Make sure to read and follow the information and labels on the nameplate, as
well as section Approvals and declarations in the appendix.
WARNING
It is strictly prohibited to use the XC-152 in order to implement safety-relevant
functions (in the sense of personal and machine protection).

1 Description
1.3 Part numbers
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 11
1.3 Part numbers
In addition to a number of basic interfaces, XC-152 compact PLCs feature
additional communication interfaces in the form of external connectors.
Figure 1: Overview of external connectors in the Compact PLC XC-152 (1) 
and external memory: SD memory card (2)
The following table provides an overview of the configurations for the avail-
able device models:
Basic interfaces Additional integrated interfaces Type Article no.
1 x Memory card 1 x Ethernet 10/100 Mbps 1 x USB device 2.0 1 x USB host 2.0 1 x RS232 1 x RS485 1 x CANopen®/easyNet 1 x PROFIBUS/MPI 1 x SmartWire-DT
✓✓✓✓ ✓---✓XC-152-E3-11 167850
✓✓✓✓ -✓✓-✓XC-152-E6-11 167851
✓✓✓✓ -✓-✓✓XC-152-E8-11 167852
✓✓✓✓ ✓✓✓--XC-152-D6-11 167855
✓✓✓✓ ✓✓-✓-XC-152-D8-11 167849
XC-152
SD-Card
XC-152

1 Description
1.4 Operator control and display elements
12 Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com
1.4 Operator control and display elements
1.5 Front
In addition to its external connectors, the device has the following operator
control and display elements in the front:
Operator control and display
elements
Function
A RUN/STOP switch Used to switch between the following PLC program operating modes:
RUN (warm start):
When the PLC program starts, the retentive (RETAIN, RETAIN PERSISTENT)
tags in the PLC program will maintain their current values.
If the PLC program is being started for the first time, a cold start will be trig-
gered even if this mode is selected.
STOP (cold start):
Before the PLC program is started, all the tags in the PLC program will be
set to their initialization values.
B RUN/STOP LED Lights up when the device is powered.
Indicates whether the PLC program is running ￫Page 65
Cc SF-LED This LED is used to indicate various device and software statuses
￫Page 65
DCOM-LED Lights up green when data is being transmitted via the CAN or Profibus
interface.
Other LED states ￫Page 65
B CD
A
Power supply 
connection
24 V DC
Location of basic
external connectors
Location of additional external connectors
The specific interfaces depend on the device model

1 Description
1.6 Service side
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 13
1.6 Service side
The device features the following controls on the service side:
Figure 2: Operator Controls on service side
Element Function
E MEM CARD-Slot Memory card (SD card) slot
F CTRL button Used to force the device to start with the DHCP function:
If the CTRL button is held down while the device is being powered up (until the
SF LED lights up green), the device will obtain an IP address via DHCP. If the
CTRL button is then held down for 5 seconds (until the SF LED flashes green),
the device will be assigned IP address 192.168.1.1 temporarily. In this mode,
the Autoexec.bat, Autoexec.reg, and Autoexec.bmp files will not be executed.
If the operating system on the memory card is invalid or is not found there to
begin with (COM LED flashing red or orange), the CTRL button can be pressed
in order to boot up with the internal operating system.
E
F

1 Description
1.7 Accessory devices
14 Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com
1.7 Accessory devices
A variety of accessories are available for Compact Controllers, for example
1.8 Nameplate
The device has a nameplate on rear. This nameplate makes it possible to
identify the device and includes the following information:
•Manufacturer
•Part number
•Article no.
•version
•Date of manufacture (Week/Year)
•Required power supply
•Serial no.
•Type approval and certification marks and information
•Layout of ports/interfaces and controls
•Permissible mounting options (top edge «Top»)
article no. Type
256487 XT-CAT5-X-2 Ethernet cross cable, 2m
256488 XT-CAT5-X-5 Ethernet cross cable, 5m
061360 ZB4-101-GF1 Fixing bracket for easy500, 700, 800, EC4P, ES4P, easy200,
MFD-CP8/CP10, XC-152
181638 MEMORY-SD-A2-S SD memory card with min. 1 GB
without operating system
139807 MEMORY-SD-A1-S SD memory card with min. 256 MByte
without operating system
NOTICE
Only use original accessories.
Order accessories through your supplier or through the Eaton
online catalog www.eaton.eu/ecat

1 Description
1.9 Support
Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com 15
1.9 Support
In the unlikely event that you run into a problem with your device, please
contact your local sales office or Eaton After-Sales Service for service and
warranty questions. When you call, please have the following information
ready:
•The exact part No. 
(see the information on the nameplate, article No. (Part No. or Art. No.))
•The date of purchase, serial number (Serial No.)
•A detailed description of the problem
Information concerning the guarantee can be found in the Terms and Condi-
tions Eaton Industries GmbH.
24-hour hotline: [phone]
e-mail: AfterSalesEGBo[email protected]

1 Description
1.10 Marine approvals
16 Compact PLC XC-152 05/17 MN050001ZU EN www.eaton.com
1.10 Marine approvals
Obtained type approvals
XC-152 compact PLCs have been granted the required shipping classification
by Det Norsk Veritas / Germanischer Loyd (DNV GL)
•DNVGL-CG-0339 type approval, November 2015 edition,
"Environmental test specification for electrical, electronic and program-
mable equipment and systems"
Certificate No.: TAA00000NC
Location classes
Installation restrictions
•Install and commission referring to XC-152 manuals
•Screened communication cables improve EMC behavior
•PE connection of communication cables improve EMC behavior
(e.g. earth-connection kit: EATON ZB4-102-KS1)
temperature BAmbient air temperature: 0°C to + 55°C

Humidity
BRelative humidity up to 100 % at all relevant temperatures.
Vibration A Bulkheads, beams, deck, bridge, acceleration amplitude: 0.7 g
emc B* All locations (including bridge and open deck)
Input Required protection according to DNV-GL Rules shall be provided upon
installation on board
* Filters / Ferrites maybe required to fulfil. See installation restrictions
Location class External connector Installation
EMC B Power Supply Place noise filter
Ethernet Place the ferrite core or snap-together ferrites at a max.
distance of 20 cm from the external device plug.
SWD communication
SWD power supply
RS485
RS232
￫￫Section "3.2 Conditions for marine approval (DNV GL)”, page
26
￫Section "3.2.1 Radio interference suppression filter for the
24 V DC supply”, page 27
￫Section "3.3.2 Screening the communication cables used”,
page 30